TRANSFER MECHANISM FOR A CONTINUOUS HEAT TRANSFER SYSTEM

Abstract

A transfer mechanism for use in a continuous cooking system includes a non-metallic counter-balance having a contact bar located toward its uppermost end and a load located toward its lowermost end. The contact bar is sized to span a useable width of the belt and the load is sized to urge the contact bar into continued contact with a portion of the belt as the belt travels around the end roller. Means such as a rotational joint is provided for pivoting the counter-balance toward and away from belt, the joint being arranged to provide a predetermined amount of travel relative to the belt. Means such as a slot is provided for adjusting a position of the counter-balance relative to the belt. The uppermost product-contact surface of the bar can be round, flat, or angled and can include grooves to reduce the amount of contact area.

Claims

1. A transfer mechanism for use in a continuous cooking system which has a first continuous belt that travels around a roller located at an end of the continuous cooking system, the transfer mechanism comprising: a non-metallic counter-balance having a contact bar located toward its uppermost end and a load located toward its lowermost end, the contact bar sized to span a useable width of the belt, the load sized to urge the contact bar into continued contact with a portion of the first continuous belt as the first continuous belt travels around the roller; means for pivoting the counter-balance toward and away from the portion of the first continuous belt, the pivoting means arranged to provide a predetermined amount of travel relative to the first continuous belt; and means for adjusting a position of the counter-balance relative to the first continuous belt.

2. A transfer mechanism according to claim 1 wherein the load is at least one physical counterweight.

3. A transfer mechanism according to claim 1 wherein the means for pivoting the counter-balance is a rotational joint.

4. A transfer mechanism according to claim 1 wherein the means for adjusting the position of the counter-balance is an adjustment slot that receives a rotational joint connected to the counter-balance.

5. A transfer mechanism according to claim 1 further comprising a scraper located on a upper surface of the counter-balance.

6. A transfer mechanism according to claim 1 wherein the counter-balance is a thermoplastic capable of withstanding a temperature of at least 200 F.

7. A transfer mechanism according to claim 6 wherein the counter-balance is a thermoplastic capable of withstanding a temperature up to 450 F.

8. A transfer mechanism according to claim 6 wherein the thermoplastic is polyetheretherketone.

9. A transfer mechanism for use in a continuous cooking system which has a first continuous belt that travels around a roller located at an end of the continuous cooking system, the transfer mechanism comprising: a non-metallic counter-balance having a contact bar located toward its uppermost end and a load located toward its lowermost end, the load sized to urge the contact bar into continued contact with a portion of the first continuous belt as the first continuous belt travels around the roller; the contact bar having an uppermost product-contact surface with a temperature rating of at least 200 F.

10. A transfer mechanism according to claim 9 wherein the uppermost product-contact surface is cylindrical-shaped.

11. A transfer mechanism according to claim 9 wherein the uppermost product-contact surface is angled.

12. A transfer mechanism according to claim 9 wherein the uppermost product-contact surface includes a plurality of grooves arranged perpendicular to a longitudinal axis of the contact bar.

13. A transfer mechanism according to claim 9 wherein the uppermost product-contact surface is tapered along a length of the contact bar.

14. A transfer mechanism according to claim 9 further comprising means for pivoting the counter-balance toward and away from a portion of the first continuous belt, the pivoting means arranged to provide a predetermined amount of travel relative to the first continuous belt.

15. A transfer mechanism according to claim 9 further comprising means for adjusting a position of the counter-balance relative to the first continuous belt.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0014] FIG. 1 is a prior art cook belt.

[0015] FIG. 2 is an isometric view of a preferred embodiment of a transfer mechanism made according to this invention.

[0016] FIG. 3 is a side view of the transfer mechanism of FIG. 2 when installed at the end of an upstream continuous heat transfer process such as a spiral oven and arranged to transfer partially cooked or fully cooked product to a belt of an immediate downstream process.

[0017] FIG. 4 is a side view of the transfer mechanism of FIG. 2 illustrating how its position and angle can be changed relative to the belt.

[0018] FIG. 5 is an isometric view of the transfer mechanism of FIG. 2 when installed at the end of a continuous heat transfer process.

[0019] FIG. 6 is an isometric view of an alternate preferred embodiment of the transfer mechanism's contact bar. The bar has a triangular profile and includes grooves along the direction of travel to reduce contact surface area. Additionally, the bar has a tapered profile along the width of the belt to create a varied length of the top product-contact surface to accommodate belts which have non-uniform characteristics across their width.

[0020] FIG. 7 is an isometric view of an another alternate embodiment of the contact bar. The bar provides a smooth, rounded contact surface to the belt, but has a flat (angled) top surface to assist in the scraping/peeling of product from the belt rather than allow thin patties to nose-dive into a rounded top surface.

ELEMENTS AND NUMBERING USED IN THE DRAWINGS

[0021] 11 Sprocket-driven belt (first belt) [0022] 13 Sprocket and roller [0023] 15 End of continuous heat transfer system (e.g. spiral oven) [0024] 17 Curved or polygonal portion of 11 [0025] 20 Counterbalance [0026] 21 Contact bar or roller [0027] 22 Grooves [0028] 23 Upper end [0029] 25 Arm or plate [0030] 26 Top (uppermost) product-contact surface [0031] 27 Load [0032] 28 Taper or tapered profile [0033] 29 Lower end [0034] 31 Pivot arm or shaft (pivot point or rotational joint) [0035] 33 Adjustment slot [0036] 35 Scraper [0037] 37 Upper surface [0038] 41 Belt (second belt)

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0039] A preferred embodiment of a transfer mechanism made according to this invention includes an inverted counter-balance 20 that is designed to, and can follow, the polygonal pattern of the cook belt 11 as the cook belt 11 travels the around the sprocket and roller 13 (see FIGS. 2-5). Cook belt 11 is of a kind well known in the art and can be a mesh- or link-style belt used in any of a number of continuous heat transfer systems commonly used to produce pre-cooked food products (see e.g. FIG. 1).

[0040] The sprocket and roller 13 is located at the end 15 of a continuous heat transfer system or process such as a fryer, water cooker, steamer, microwave, infrared system, or linear or spiral oven (not shown). Counter-balance 20 assists in the transfer of the product cooked or par-cooked by the heat transfer system to a belt 41 of the next immediate downstream process. Typically, belt 41 is arranged at a lower elevation than belt 11.

[0041] Preferably, the angle and position of the counter-balance 20 is adjustable, as is the load 27 applied on the counter-balance 20. The load 27, which can be determined through calculation and routine experimentation, is selected for the specific belt 11, conveyor placement/angle, speed, and product type of the pre-cooked food product application. Adjusting means such as an adjustment slot 33 or its equivalent allows for the proper conveyor placement/angle of the counter-balance 20 (see FIG. 4).

[0042] The counter-balance 20 includes a contact bar or roller 21 located at the upper end 23 of the counter-balance arm or plate 25 and a load 27 located toward the lower end 29. Contact bar 21 is not limited to a round or cylindrical shape (see FIG. 2) but can be any shape preferable and appropriate for the specific application, such as a triangular profile or containing variation across the belt width. For example, in one preferred embodiment the bar 21 has a triangular profile and includes grooves 22 along the direction of travel (perpendicular to a longitudinal axis of the bar 21) to reduce contact surface area (see FIG. 6). Additionally, the bar 21 has a tapered profile 28 along the width of the belt 11 to create a varied length of the top product-contact surface to accommodate belts 11 which have non-uniform characteristics across their width. In another alternate embodiment of the contact bar 21, bar 21 includes a smooth, rounded contact surface to the belt 11, but has a flat (angled) top product-contact surface 26 to assist in the scraping/peeling of product from the belt 11 rather than allow thin patties to nose-dive into a rounded top surface. (see FIG. 7).

[0043] The load 27, in combination with pivoting means such as a pivot arm or shaft 31, allows the bar 21 to be in constant contact with a curved or polygonal portion 17 of the belt 11 along a usable width W of the belt 11 but does not inhibit the speed at which the belt 11 moves around (or about) the roller 13. If there is an isolated high spot on belt 11, the high spot will generally be in a flexible (unsupported region) where the applied force (if great enough) will press or flatten the high spot in the flexible portion. Generally, high spots are more specific to the linear direction of belt travel, either through the previously mentioned rotation of a polygon or through a wire mesh overlay that has the potential to create a high spot as the belt travels around the shaft.

[0044] Pivoting means other than shaft 31 can be used to provide a rotating joint. For example, a pin or bolt and bushing combination or a bearing can be used.

[0045] The material used for counter-balance 20 is preferably one that is non-metallic, low friction, food-grade (FDA-compliant) material that can withstand, at a minimum, 200 F. and, more preferably, at least 450 F. In other embodiments, the material can withstand temperatures up to 800 F. A suitable material is an engineering thermoplastic such as polyetheretherketone (PEEK) or its equivalent, which is typically rated up to 500 F. RULON 641 PTFE-based resin (Saint-Gobain Performance Plastics Corp., Aurora, Ohio) is another high temperature food-grade plastic that is rated up to 550 F. Other suitable materials can include a food-grade ceramic or its equivalent. Unlike prior art transfer mechanisms, no gap is required between the contact bar 21 and the belt 11 because counter-balance 20 is non-metallic.

[0046] When the belt 11 forms a temporary bump or peak, the counter-balance 20 pivots away but maintains contact with the belt 11. After the bump or peak passes, the counter-balance 20 pivots toward the belt 11, again maintaining constant contact with the belt 11. The counter-balance 20 provides for travel through a predetermined angle , and is preferable an angle that prevents the bar 21 or other portions of the transfer mechanism from coming into contact with the belt 41 of the downstream process.

[0047] A scraper 35 is located on the upper surface 37 of the counter-balance 20. The balance 20 also allows the scraper 35 to maintain contact with the belt 11 but move out of the way when a temporary flaw in the belt 11 is encountered. The scraper 35 may have any kind of edge preferable and appropriate to the application. For example, a scraper 35 having a sharper edge than the one shown here can be used (yet still be capable of moving out of the way when required).

[0048] Load 27 is illustrated as plurality of physical counterweights. However, applying a load to the belt surface can be done with different methods such as but not limited to springs and pneumatics. Regardless of the method used, what is important is that a sufficient load be applied to the counter-balance 20 so that it maintains contact with the belt 11 as it moves around roller 13 but can move or pivot awayagain, maintaining contact with the belt 11when a flaw is encountered. By way of a non-limiting example, counterweights of between 24 and 48 lbm were applied, which translated to approximately 12 to 25 lbf of contact force from the scraper on the belt. This, in turn, corresponded to between 0.3 and 0.7 lbf applied per inch of belt width. The force necessary in any specific application is dependent on a number of variables, including but not limited to belt type, operating conditions, speed, and scraper/belt configuration.